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When an Installed PJP Conveyor System was no Longer the Best Solution

When an Installed PJP Conveyor System was no Longer the Best Solution

Oct 28, 2025

Case Studies

When an Installed PJP Conveyor System was no Longer the Best Solution

An automotive client’s changing needs

In 2024, we designed and supplied a chain-to-chain powered roller system for a vehicle component manufacturer. The conveyor fed onto a PJP pallet lift unit which transported pallets with a very specific dimension upstairs.

This year, the client made the decision to make the system more flexible, in particular, to be able to carry pallets of different shapes and sizes. And also, to give them different destinations.

We were pleased to help.

Adapting existing custom conveyors into a new bespoke solution

We modified the infeed area to accommodate a ramp to side load the pallets with a pump truck. The infeed originally had an inline ramp so we had to create a pivoting section. This meant that the pump trucks could load pallets horizontally from the side.

We then engineered the system so that once the pallet arrives on the conveyor, it pivoted up to match the original angle. Nifty eh?

The new expanded pallet ranges gave us two forms of complexity. Firstly, the composition of the pallet bottoms were all different. Secondly, they now had different places that they needed to get to.

We decided to dispose of the current 90-degree chain transfer which travelled into the lift area. We replaced it with a 90-degree turntable. This meant pallets could now travel either through the turntable to another offload area or be rotated to enter the lift area: the destination being dictated by an overhead scanner unit.

Pallet System Modules

Intersection Point

Roller Conveyor Section

Pallet Lift Approach

All set for the future

This is a great example of a business’s operational need changing and PJP successfully re-engineering their materials handling to use as much of the original system as possible. The client ended up with custom conveyors built into a system that was fully engineered to meet their precise needs.

Building flexible systems is something we’re good at.

But don’t take our word for it – get in touch to talk through your system requirements and we’ll take on the challenge of designing and building you a flexible solution that meets you needs.

Tel: 01623 354473  email: sales@pjpconveyors.co.uk

Making Pallets Live Longer in Harsh Manufacturing Environments

Making Pallets Live Longer in Harsh Manufacturing Environments

Jul 23, 2025

Case Studies

Making Pallets Live Longer in Harsh Manufacturing Environments

The Challenge: Mitigating Extreme Pallet Wear

In demanding manufacturing settings, the lifespan of essential equipment can be drastically cut short due to the environmental stresses they face. In fact, this construction materials company faced a constant challenge of rapid and costly wear to their pallets.

And these are no ordinary pallets.

They are made of steel and weigh 115kgs each empty! These pallets also have unusual measurements of 1400mm wide x 700mm long x 15mm thick. Furthermore, they endure a tortuous working life bearing constant heavy building material loads. This means frequent replacements, operational downtime when they fail and “£££” to replace them.

We were sought to present a solution that would help the manufacturer get the maximum life out of their hefty pallet investments. To this end we proposed a solution that would periodically turn over the pallets in order to evenly distribute wear and tear.

This had the potential to extend the pallets’ operational life, reduce replacement costs and minimise disruption to the customer’s production flow.

 

The Solution: A Bespoke Automated Pallet Turnover Unit

We designed, built, and installed a custom-engineered solution: a new Automated Pallet Turnover Unit. To be sure it was up to the job we integrated it with a heavy-duty twin chain conveyor.

This beefy 180-degree turnover device is specifically tailored to handle the user’s unique pallet dimensions and weight. It operates at an impressive rate of one cycle every nine seconds.

At the heart of this innovative system is a specially designed Destaco cam box. This critical component features inbuilt damping properties. These are crucial for managing the huge vibrations inherent in turning over such heavy items at speed. The box’s clever design also significantly reduces the need for complex electronic controls and additionally streamlines the system and enhances reliability.

The entire unit was meticulously designed and built in our workshops, undergoing rigorous testing to ensure optimal performance and durability. This pre-installation preparation was particularly vital, given we only had very limited installation time.

The Outcome: Enhanced Durability and Operational Efficiency

The installation of the Automated Pallet Turnover Unit was successfully completed within a very tight factory shutdown window of just two days. The immediate impact was clear:

  • Reduced Pallet Wear. By regularly turning over the steel pallets, the wear distributes evenly across both faces to significantly extend the pallets’ lifespan.
  • Cost Savings. From lowered pallet replacement costs
  • Improved Operations. The robust and reliable nature of the bespoke unit ensures smoother production flow and reduces unexpected downtime caused by pallet failures.
  • Streamlined Controls. The special cam box simplifies the overall control system to ease maintenance requirements.

This project is a great example of how tailored engineering solutions can address challenges in the harshest industrial environments. It also illustrates the significant improvements possible.

Building the unit in the factory

Building the unit in the factory

Inner workings of machine and motor

Inner workings of machine and motor

Heavy duty chain section

Heavy duty chain section

Turnover unit side profile

Turnover unit side profile

Now let us help you

Why not work with us to prolong the life of your equipment. We can handle even the heaviest of challenges. Contact us, we’d love to hear from you.

Streamlining Pallet Handling: A Chain Conveyor System Design

Streamlining Pallet Handling: A Chain Conveyor System Design

Feb 5, 2025

Case Studies

Streamlining Pallet Handling: A Chain Conveyor System Design

Efficient pallet handling is crucial for any warehouse or manufacturing operation. Recently, we tackled a project requiring a robust and precise system to move heavy pallets loaded with paper through a loading and packaging process.

The challenge: heavy pallets, precise movement

Our customer needed a conveyor system capable of handling substantial pallet weights while concurrently maintaining accurate positioning for subsequent operations. The key requirements were:

  • Pallet Dimensions: 1200 x 800mm
  • Throughput/Speed: 12 meters per minute
  • Pallet Weight: 1000 kg
  • Orientation: Wide edge leading
  • Integration: Seamless transfer to a customer-supplied pallet loading station with a servo drive (a sophisticated electronic motor that controls a very precise movement), followed by a two-way strapping and wrapping station.
  • Discharge: Presentation of finished pallets for forklift truck (FLT) offloading.

These specifications presented a number of challenges. The heavy pallet weight demanded a robust conveyor design. Furthermore, the required speed and precise transfer to the loading station meant accurate control and smooth movement. Finally, integration with the customer’s existing servo drive and subsequent packaging equipment was essential.

The solution: robust design and complete control

Our proposed solution was a combination of proven technology and careful design:

  • Low Profile Triple Chain Conveyors: We specified heavy-duty, low-profile triple chain conveyors using 5/8 pitch chains. This design gives the strength and durability to handle 1000kg pallets while the low profile simultaneously makes for easy loading and unloading. The triple chain configuration ensures even weight distribution and smooth pallet movement.
  • Compact 180-Degree Rotation Turntable: A compact, 180-degree rotation turntable was incorporated to precisely orient the pallets. In addition, the turntable features an externally mounted gearbox and motor for easy maintenance and accessibility.
  • Braked Motors: Braked motors were included to ensure precise stopping and positioning of the pallets.
  • Customer Servo Drive Integration: Seamless integration with the customer’s existing servo drive was a key element of the solution. For the most part, this was to allow precise control in placing the pallets where they were needed in the operation.
  • Conveyor Bridging Transfers: To facilitate smooth and seamless pallet transfers at conveyor intersections we introduced conveyor bridging transfers to add additional support and regulation.

The turntable section design

Paper handling new invention

The outcome

This comprehensive solution addresses all of the customer’s requirements to provide a significantly robust, efficient, and accurate pallet handling system. The combination of heavy-duty components, precise control mechanisms and seamless integration undeniably ensures a smooth operation and optimal throughput.

In summary, we have delivered a great solution that has been a game changer for this customer’s pallet handling by carefully considering their needs and applying our expertise in conveyor system design.

The design becomes a reality

Paper handling new invention

Need help with pallet handling?

We have the brains and the muscle to get you the perfect tailored solution that can handle even the heaviest pallet. Call us on 01623 354473 or see the other ways you can get in touch.

Paper Handling – PJP’s Perplexing Paper Project

Paper Handling – PJP’s Perplexing Paper Project

Oct 3, 2024

Case Studies

Paper Handling – PJP’s Perplexing Paper Project

Paper comes in all shapes and sizes

A customer approached us wanting a turnkey solution for handling paper.

Sounds easy?

Well…

Several issues made their request a challenge. One particular obstacle was the need to centralise round discs of paper, that could be of different diameters, onto a conveyor. In fact, the product could weigh up to 50 kgs and have a diameter ranging from 300-600mm.

 

Design skills at the ready for paper handling

PJP pondered the issue before using our specialist design capabilities to create a simple, cost-effective bespoke solution in both 2D and 3D drawing packages. We worked with the customer, using and valuing their input from the initial concept design stage through to detailed design… and the eventual manufacturing of the solution.

A new paper handling invention: the product centraliser

The resulting ‘product centraliser’ that we created was able to centralise a paper core product to within 1-2mm of the conveyor centre line. This meant that the customer’s overhead robot could pick and place its gripper to into the core of the product exactly on the centre line of the conveyor. It would then lift and transfer the product onto awaiting pallets.

The solution also included an overhead timing belt system to accurately move the centralising mechanism in conjunction with a low friction modular belt conveyor which reduced wear on the base of the product.

Not just a pretty face

This is a great example of listening to the customers complex requirements, using our experience and creating an ingenious new paper handling system. Another bespoke solution designed and manufactured by PJP Conveyors.

We are more than just a conveyor company!

 

Paper handling new invention

Now you’ve seen what we can do, why not see if we can help you

Please get in touch with any new handling ideas you are thinking about introducing into your business – no matter how difficult they sound.

PJP and the Chocolate Factory – A Pallet Conveyor System

PJP and the Chocolate Factory – A Pallet Conveyor System

Aug 6, 2024

Case Studies

PJP and the Chocolate Factory – A Pallet Conveyor System

A pallet conveyor system has a mighty challenge

Pallets are essential for streamlining production flow and managing storage capacities, however, they can weigh an absolute tonne! Incredibly robust roller conveyors and fully bi-directional pallet lifts feature on this PJP pallet conveyor system which certainly offers flexibility and strength to transfer pallets.

A heavyweight system with tasty outputs

This system can easily handle a heavyweight pallet challenge. It transports, lifts and lowers multiple sized pallets weighing up to 1500Kg. The items that sit on the pallets vary a lot. One might contain tubs of powder, packaging materials, factory waste or finished goods, which in this case is delicious chocolate confectionary.

Horizontal and vertical journeys

Delivery waggons bring in the pallets. Special forklift load centre points ensure a safe transfer from trucks to a large transport conveyor.

Multiple locations then beckon. Pallets could travel along one level to go into bulk storage. Alternatively, they may need to be diverted to one of many operational locations on the first floor. Bespoke pallet lifts, specially designed and installed by PJP, transport the items up and down if this is the case.

No danger of hitching a ride on these lifts

Pallets feed in and out of the lifts in single file via dedicated pallet conveyor lanes. These conveyors include light guards at all entry and exit points to safely prevent operator access. This means only pallets can enter the system. If any other transport medium (or person) attempts to gain entry into a lift, the system instantly stops and requires manual resetting.

Safety is always important in material handling applications, but its importance is paramount when lifting and lowering heavy loads!

Exceptional results

This system is now used 24 hours per day, 5 days per week and has completely transformed operations on site. We have certainly created remarkable productivity increases in many processes with this system.

Want to see how we can help you?

This is just one examples of PJP’s successful projects. We deliver success for our customers and we’re proud of that. Contact us to see how we could help you achieve your ambitions.

Pallet conveyor system - pallet lift
Pallet conveyor system lift at its top level